Sheet of articulated masonry-like units and method for producing the same

ABSTRACT

The present invention provides a sheet of articulated masonry-like units (SAMU) and a method for producing the same. The method comprises obtaining masonry-like units prepared from one or more hardening materials; placing said masonry-like units into an articulating structure; interconnecting the masonry-like units to each other using a mesh-adhesive thereby generating a SAMU. Kits for preparing such sheets and methods of installing the same are also provided.

RELATED APPLICATION

[0001] This application claims priority from Canadian Patent ApplicationNo. 2,324,019, filed Oct. 20, 2000, that is incorporated herein byreference.

FIELD OF THE INVENTION

[0002] The present invention relates to decorative facing materials.

BACKGROUND OF THE INVENTION

[0003] Masonry materials such as brick and natural building materialssuch as stone or marble are often used to decorate walls due to theunique and inherent beauty of the finished product, their durability andmaintenance free attributes. Since no two pieces of masonry-likeelements look exactly the same, each wall comprising these componentswill also be unique, which is part of the artistic beauty of these typesof decorating materials. The “earthy” look of brick with wood beams, forexample, can render an interior warm and interesting. Moreover, thesetypes of materials also serve the functions of providing temperatureinsulation and reducing exterior noise. A major disadvantage ofconventional brick construction is that it is expensive, laborintensive, and normally must be done by professional masons.

[0004] There are different strategies in the prior art used to simulatethe appearance of masonry material, for example brick, other mortar andsand based products such as stucco, and natural building materials suchas stone or marble. Familiar products include pre-decorated plywoodproducts or other forms of wood based products that simulate the look ofmasonry elements such as brick. More complex methods of achievingsimulated masonry-like elements range from synthetic copolymers andresins, to the construction of composite and bulky masonry-like piecesglued onto heavy backing boards or support frames. Such methods aregenerally expensive to produce, are usually heavy and furthermore, suchmethods require an elaborate process of manufacture.

[0005] Apart from the decorative limitations, most artificial panelshave the disadvantage of being heavy with poor insulating properties.They are susceptible to fracture if dropped or struck and they lackflexibility in that slight bending stresses induce inappropriatecracking. Moreover, each of these synthetic strategies involves the useof rigid, non-flexible surface coverings that greatly restrict ease ofuse and limit the surface contours to which they can be applied tolinear planes.

[0006] Some examples in the prior art that attempt to develop methodsand strategies of simulating masonry elements, for example brick wallmaterial, are disclosed in U.S. Pat. Nos. 4,644,719, 4,646,722,5,228,937, 5,373,675, 5,787,666, 5,792,511, 5,974753, 6,041,561,6,164,037 and 6,240,691 as well as published U.S. patent application No.2001/0023559 A1. One such technique is disclosed in Pat. No. 5,228,937wherein a panel, simulating in this instance a brick wall, isconstructed using a stiff backing member, an impermeable sheet with aplurality of horizontal shelves upon which a plurality of spaced apartfull sized masonry brick-like units are adhesively attached to the sheetand grouting mixture is applied between the spaces to cover the entirepanel. This method requires that a rigid backing be used as a supportingmechanism for the brick panel which in turn allows for no flexibility inthe finished product. This lack of flexibility prevents the use of thepanel in any type of construction setting save for flat surfaces.Further, a plurality of screws and nails are used in order to secure thebricks to the rigid support panel, a mechanism which encourages cracksand stress fractures within the panel structure itself. This methodsuffers from the disadvantage of producing a relatively heavy, thick andstiff panel that is not useful for widespread decorative application.

[0007] Another example of a method that simulates a wall constructedfrom masonry material is disclosed in U.S. Pat. No. 5,373,675. Thiscomposite building system suffers from the disadvantage of beingextremely heavy and hard to maneuver safely, thus posing a safety hazardto workers. In addition, the process of making such a composite buildingsystem requires a substantial amount of reinforcing material whichitself is heavy and not flexible. Finally, this method results in a veryrigid panel made of concrete and metal reinforcements which must bemoved into place with the use of heavy equipment, increasing the costand time of production.

[0008] U.S. Pat. No. 6,041,561, is directed to a self-contained moldedpre-fabricated building panel and a method of making the same. Theself-contained panel includes: a steel skeletal assembly comprising anarray of steel channels and rigid sheeting, a forming structure tosurround the skeletal array, a self-hardening material such as concretethat is introduced into the forming structure, and a molding with ameans to enable press-setting thereof in a wet concrete wall.Disadvantages of such a self-contained pre-fabricated building wallinclude the following. One, walls made with this method contain heavysupport and load bearing structures that make assembly of the wall andmoving the finished product difficult. Two, construction of apre-fabricated wall as disclosed in Pat. No. 6,041,561 is verycomplicated and if it is to be built correctly, must be completed by aprofessional builder. Therefore, using such a method to construct apre-fabricated wall made with simulated masonry elements is not amenableto a worker of limited skill in the art. Finally, in order for such awall to be used as a structural support in a building it must meetsafety standards. Therefore, an inspection by a qualified structuralengineer must be performed which would increase the construction costs.

[0009] U.S. Pat. No. 6,164,037, is directed to a formliner for producinga decorative panel made up of a layer of concrete which interconnects alayer of spaced apart bricks secured in a layer of concrete orcementitious material. Disadvantages of such a formliner include thefollowing. One, a decorative wall formed using the formliner describedin U.S. Pat. No. 6,164,037 is rigid, heavy and not flexible andtherefore, can only be placed on flat surfaces. The heavy weight of afinished panel produced using the formliner makes it awkward for aworker skilled in the art to properly attach the panel to a supportstructure. Two, a preferred method of attachment for a decorative panelto a support structure is nailing or screwing, which may damage or marthe appearance of the bricks forming the decorative face of the panel.Three, the decorative look of a finished panel cannot be adjustedwithout substantially changing the look of a formed panel. For example,more grout-material may have to be added to a panel in order to fill inopen spaces, and because the panels produced with the formliner arecured before adding a grout material, cracking or decay of thedecorative facing may occur due to insufficient bonding of the addedgrout-material to the panel.

[0010] Published U.S. patent application No. 2001/0023559 A1, isdirected to a process for making brick-faced construction material andto brick-faced blocks made by the process. Disadvantages of such amethod include the following. One, individual foamed resin base-blockshaving an adhesive layer are laid free-hand on top of the base-side ofuncured bricks within a molding unit. Once the foam resin base blocksare laid free-hand without any type of guiding mechanism their positioncannot be adjusted because they are bonded to the uncured bricks. Such aprocedure is tedious and lends itself to a high degree of error whenforming a brick-faced construction. Two, the entire brick-facedconstruction must be removed from the silicone mold in one unit, aprocedure that is very difficult to perform and often leads to damagedbrick material or separation of the bricks form the foamed-resin baseblocks in the finished product. Third, a finished brick-facedconstruction is not flexible, making transport of the fished product toa construction site very difficult. Four, a brick-faced constructionmust be supported by reinforcing material, usually in the form ofconcrete, at a construction site, adding yet another step to finish offthe brick-faced construction. Thus, the procedure to make a brick-facedconstruction, using the method disclosed in U.S. patent application No.2001/0023559 A1, is quite laborious and time consuming.

[0011] Due to these types of limitations in the prior art a need remainsfor a light weight decorative wall covering that simulates masonryelements such as brick or concrete or natural building materials such asstone or marble, is economical, flexible, and easy to produce and apply.

[0012] This background information is provided for the purpose of makingknown information believed by the applicant to be of possible relevanceto the present invention. No admission is necessarily intended, norshould be construed, that any of the preceding information constitutesprior art against the present invention. Publications referred tothroughout the specification are hereby incorporated by reference intheir entireties in this application.

SUMMARY OF THE INVENTION

[0013] The present invention provides a sheet of articulatedmasonry-like units and method for producing the same. One aspect of theinvention provides a method of forming a sheet of articulatedmasonry-like units using the sequential steps comprising: obtainingmasonry-like units having a base portion ranging in size from about ⅛ to2 ½ inches in thickness prepared from one or more hardening materialsselected from the group gypsum cement, plaster of Paris, Portlandcement, an acrylic-based resin with cementitious material andcementitious material; placing said masonry-like units into anarticulating structure with a plurality of separate holding cavities tohold one or more masonry-like units at least {fraction (1/16)} of aninch above the height of the upper edge of said articulating structure;interconnecting the masonry-like units to each other using amesh-adhesive thereby generating a sheet of articulated masonry-likeunits, wherein sufficient space is present between each masonry-likeunit sufficient to enable an installation or filler material to enterbetween adjacent masonry-like units and pass through the open weaveportions of said mesh adhesive.

[0014] One further aspect of the invention provides a kit to produce asheet of articulated masonry-like units comprising separately; anarticulating structure shaped to simulate any wall, ceiling, or buildingtype structure constructed with masonry units; masonry-like units; meshnetting means; adhesive; adhesive application means; mortar material(s);and instructions for use.

[0015] One further aspect of the invention provides a kit having a sheetof articulated masonry-like units comprising separately; a sheet ofarticulated masonry-like units; mortar material(s); and instructions foruse.

[0016] One further aspect of the invention provides a sheet ofarticulated masonry-like units produced by the method using thesequential steps comprising: obtaining masonry-like units having a baseportion ranging in size from about ⅛ to 2 ½ inches in thickness preparedfrom one or more hardening materials selected from the group gypsumcement, plaster of Paris, Portland cement, an acrylic-based resin withcementitious material and cementitious material; placing saidmasonry-like units into an articulating structure with a plurality ofseparate holding cavities to hold one or more masonry-like units atleast {fraction (1/16)} of an inch above the height of the upper edge ofsaid articulating structure; interconnecting the masonry-like units toeach other using a meshadhesive thereby generating a sheet ofarticulated masonry-like units, wherein sufficient space is presentbetween each masonry-like unit sufficient to enable an installation orfiller material to enter between adjacent masonry-like units and passthrough the open weave portions of said mesh adhesive.

DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 provides a schematic of masonry-like units afterpreparation and curing of the units subsequent to their removal from ahigh definition mold.

[0018]FIG. 2 provides a schematic of masonry-like units having acurvilinear base and a sample mold that may be used to form masonry-likeunits of this type of configuration.

[0019]FIG. 3 depicts three different exemplary pattern types of highdefinition open tray molds. Each mold may be designed to produce anyshaped pattern for the masonry-like units of

[0020]FIG. 4 depicts an example of a high definition mold in the shapeof a cornered brick pattern. Light weight masonry-like units in theshape of bricks cure within the high definition mold. These brick-likeunits will be used to form a SAMU of a similar structure by placing thecured brick-like units in a form matched articulating structure in theshape of a cornered brick pattern.

[0021]FIG. 5 illustrates how a completely constructed SAMU can be foldedor rolled for packaging into a kit format for sale to the public.Similarly, the components that make up a finished SAMU, the highdefinition mold, masonry-like units, mesh, articulating structure, andglue etc. can be sold in a kit.

[0022]FIG. 6 depicts three different exemplary patterns of articulatingstructures: A) a flagstone shaped pattern; B) a brick wall pattern and;C) a structure demonstrating how four different types of non-naturalmaterials patterns can be produced using this method.

[0023]FIG. 7 depicts a worker designing, in this instance, a customizedbrick wall shaped pattern for a SAMU. In this embodiment light-weightgypsum brick-like units are placed in an articulating structure having abrick wall pattern using a desired color arrangement of the bricklikeunits.

[0024]FIG. 8 depicts a customized brick-like arrangement set in thearticulating structure. In tis embodiment, gypsum brick-like units areloaded into the articulating structure front face down. Further, eachbrick-like unit extends out of the articulating structure so that theSheet of Articulated Masonry-like Units (SAMU), once constructed, willdry separately away from and above the articulating structure, thuspreventing the SAMU from drying attached to the articulating structure.The design also allows for the easy removal of the SAMU from thearticulating structure.

[0025]FIG. 9 depicts the finished product, a light weight, flexibleSAMU. In this example the SAMU bears a customized pattern in the shapeof a brick wall. In this figure the orientation of the SAMU is facedown.

[0026]FIG. 10 provides a schematic of the articulating structure and across sectional view of the articulating structure at various stagesduring the manufacturing of a SAMU.

[0027]FIG. 11 provides a schematic of a SAMU after the application of amesh-adhesive.

[0028]FIG. 12 illustrates a worker completing the construction of aSAMU. In this embodiment, a lightweight porous mesh is placed on top ofthe masonry-like units following application of a glue adhesive to theback face of the masonry-like units. In this embodiment the masonry-likeunits are laid out in a brick-wall pattern set in the articulatingstructure. The mesh is further adhered to the masonry-like units madefrom gypsum material by applying a second coat of glue adhesive onto andthrough the mesh material with a brush, such as a paint brush or a foamroller. Once the glue has dried, thereby forming a SAMU simulating abrick wall, the entire brick-like unit and mesh assembly is peeled awayfrom and out of the brick-like unit wall shaped articulating structure.

[0029]FIG. 13 depicts a SAMU with a brick wall pattern applied to asupporting wall. The top perimeter mesh of the SAMU may be attached to asupport which may be attached to the wall if desired. To adhere the SAMUto the wall, mortar, or a similar substance, is applied to the wall andthe SAMU is pressed onto the wall. A worker then removes excess mortar,or adds additional mortar, with a mortar-trowel until a desired finishedlooked is reached.

[0030]FIG. 14 depicts a magnified view of FIG. 6, and shows the detailof the finished product, a SAMU.

DETAILED DESCRIPTION OF THE INVENTION

[0031] The following description illustrates the invention by way ofexample, not by way of limitation of the principles of the invention.The description will clearly enable those skilled in the art to make anduse the invention described herein. The description includes a number ofexamples of the many variations and adaptations that are possible usingthe method of the present invention.

[0032] The present invention provides for methods of designing, makingand using a Sheet of Articulated Masonry-like Units, SAMU. Themasonry-like units used to make a SAMU may be produced in a manner thatreflects the look of any type of natural material used in the art ofmasonry, for example, stone, marble, adobe, brick, distressed brick,blasted rock, irregular stonework, carved stone.

[0033] A SAMU is a one-piece sheet that can be attached to a wall,closely juxtaposed to other SAMUs to form a decorative pattern for awall. One SAMU may or may not be identical in construction to another,wherein the aesthetics of each SAMU can depend upon the desired outcomeand design of the fmal network of SAMUs. A SAMU can be produced suchthat it is flexible, light-weight and inexpensive relative to naturalmaterials and. In addition a SAMU may be constructed such that it iswater impermeable. A SAMU can also be constructed in a manner enablingit to be folded or rolled for shipment or storage. Furthermore, a SAMUcan be constructed for interior or exterior use, wherein the environmentin which a particular SAMU may be installed can depend upon the typematerials used to construct the SAMU and attach it to the surface.

[0034] As an overview, the method of making a SAMU comprises the stepsof (a) preparing a high definition open tray mold; (b) mixing a fluentgypsum cementitious material and if necessary adding an appropriate dyecolor to the mix; (c) filling the mold with the fluent gypsumcementitious material to make a plurality of masonry-like units; (d)allowing the masonry-like units to cure and harden in the mold; (e)removing the masonry-like units from the mold; (f) laying themasonry-like units front face down in a form-matched articulatingstructure in order to form a desired pattern; (g) overlaying themasonry-like units contained in the articulating structure with amesh-adhesive; (h) allowing the SAMU to dry; and (i) removing the SAMUfrom the articulating structure.

[0035] Masonry-like Units

[0036] Masonry-like units are shaped to simulate masonry material suchas bricks, concrete blocks or may be shaped like natural materials usedin the masonry art for example, stones, flagstones or marble. Themasonry-like units can be made from gypsum or a similar material anddescribed herein, may be made in any color, in particular, colors thatresemble natural masonry-like material for example bricks, stones ormarble.

[0037] Masonry-like units are generated by preparing and pouring ahardening material, preferably gypsum cement into a high definition openmold. The hardening material can be of many types, the definingcharacteristics include the fact that, within a practical period of timeafter mixing with an appropriate dilutent, for example water, thematerial hardens and does not crumble or otherwise significantly looseits integrity over the lifetime of the SAMU. Interior surfaces may crackin such a manner to further add to its “realistic” appearance, as longas the integrity is maintained such that the material does not spall.The hardening material may be any cementitious or non-cementitiouscompound, preferably but not limited to gypsum cement, portland cement,plaster-of-Paris, an acrylic based compound. The material chosen candepend upon the desired final texture as well as considerations ofweight, wear and costs of the project.

[0038] In one embodiment an appropriate amount of gypsum cement isprepared by mixing water and gypsum cement in an approximate ratio, forexample one part water to four parts dry gypsum cement, said mixturebeing stirred or mixed until all lumps have dissolved, resulting in athick smooth consistency. The mixture is then poured separately into theindividual cavity or cavities of the high definition mold and spreadwith a tool, for example a trowel to smooth the base surface of themasonry-like unit. Appropriate dyes may be added to the mixture duringthe initial mixing of the hardening material or may be placed on theinterior surfaces of the high definition mold, in order to simulate thecolor of the appropriate masonry-like unit to be produced. Colors mayinclude, but are not limited to, burnt orange, orange, red, gray, black,brown, tan, beige, or white.

[0039] The masonry-like units 300 can be envisioned as having twosections, as indicated in FIG. 1: a base portion 310 and a highdefinition or decorative face portion 320, shaped by the high definitionmold 330.″. In one embodiment the base portion 310 of the masonry-likeunits 300 is approximately ⅛″ to 2.5″, and in a further embodiment thebase portion of the masonry-like units ranges between approximately ⅛″to 2″ and yet a further embodiment the base portion of the masonry-likeunits ranges between approximately ⅛″ and 1″.

[0040] In one embodiment of the present invention, if the masonry-likeunits are of a heavier nature, for example the base portion of the unitis larger than 1.5″, the masonry like units may be formed such that thehardening material in the interior of the masonry-like unit is replacedwith a less dense material thus reducing the mass of the unit. Thesurface area of this type of masonry-like unit will still be formedusing the hardening material, in order that the desired physicalfeatures of the unit can be produced.

[0041] In one embodiment of the present invention as illustrated in FIG.2, the base portion of the masonry-like units is shaped in a curvilinearfashion, providing a means for a SAMU constructed using this form ofmasonry-like units to be installed around a curved surface, for examplea circular column. In addition, the curvilinear base of a masonry-likeunit may be concave or convex wherein this curvilinear shape may bedependent on the particular application for a SAMU constructed usingthese forms of masonry-like units.

[0042] Masonry-like units are typically cured in the molds for about 4to 24 hours. One skilled in the art will envisage longer curing timesfor masonry-like units having greater thicknesses. Once the masonry-likeunits are made and cured they are removed from the high definition mold,a process known as demolding, placed into an appropriate pile based oncolor or size, and appropriately stored until required. However, removalof the masonry-like units may occur in as little a 30 minutes, whereinthis time frame being determined by the type of material used to formthe units.

[0043] In FIGS. 1 and 2 the back surface of the masonry-like units isillustrated as a smooth surface. In reality this surface may not besmooth but it may have a rough texture which can provide an improvedsurface to which a mesh adhesive may adhere.

[0044] The High Definition Open Molds

[0045] Masonry-like units are prepared in a high definition open molds.The simplicity of the high definition mold renders freedom to designalmost any size, type and shape of masonry-like unit needed in theconstruction of a sheet of articulated masonry-like units (SAMU), anddramatically decreases the time and cost of producing and constructingmasonry-like units.

[0046] As illustrated in FIG. 1, a high definition mold 330 is formedsuch that the masonrylike unit 300 may be easily removed from said mold.In addition, the high definition mold 330 provides a means for preparingmasonry like units having high definition faces which simulate masonrytype components, in a cost effective and simple manner.

[0047] In one embodiment of the present invention and with reference toFIG. 3, high definition open tray molds 100 are made of silicone. Aplurality of smaller cavities 110 are contained within a larger opentray cavity 140. Further, each cavity 110 may contain distinctive highdefinition markings 120. The plurality of cavities 110 have a depthlower than the open tray cavity 140, which is shown in perspective bythe dashed lines 130. The high definition open tray mold may be designedin order to produce any type or shape of masonry-like unit asillustrated in FIGS. 3A-C. Using the masonry-like units and method ofthe present invention, it is possible to create a pattern that is notentirely repetitious in its fine detail. This design feature is lostwith all other artificial coverings or masonry structures because thecost of producing such a large surface area warrants a repetitivedesign.

[0048]FIG. 4 depicts one example of a high definition mold in the shapeof a brick wall corner. The masonry-like units formed using thisparticular mold may form the corner pieces of a SAMU to be utilized as adecorative covering for a fireplace or any other support structure withcorners for example.

[0049] In one embodiment of the present invention, high definition moldsmay be designed to form masonry-like units that have convex or concavecurves in order to be used to make SAMUs as decorative coverings forrounded support structures like pillars or columns. With reference toFIG. 2 sample molds for a brick like unit and a stone like unit havingconcave bases are illustrated. As would be known to a worker skilled inthe art, a mold used to create a curvilinear surface on the base of amasonry like unit would typically have to be modular in construction, inorder to provide a means for the removal of this form of a masonry-likeunit since the high definition face may prevent the de-molding of amasonry-like unit formed in a single entity mold. In particular, themold can be formed from two sections which are interconnected to formthe complete mold, wherein the two sections are connected by aconnection system which is easily disconnected and reconnected for theremoval and reuse of the mold.

[0050] In a further embodiment of the present invention, masonry-likeunits having a concave or convex back surface may be constructed throughthe bending of a high definition open molds such that the mold has thedesired curvature. Upon completion of this step the hardening materialis placed in the high definition molds and allowed to cure. In addition,masonry-like units having a back surface which is curved may be producedusing a process similar to that previous mentioned, however thehardening material is poured into the molds in a two step process.First, hardening material having a typical consistency is poured intothe molds such that the high definition surface of said mold is coveredby the hardening material. A second batch of hardening material isprepared which has a much stiffer consistency by, for example byreducing the volume of water in the mix, such that this second batch ofmaterial is able to maintain the curved shape on the back surface of themasonry-like units. This second batch of hardening material is placed inthe molds completing the formation of the masonry-like units.

[0051] In one embodiment as illustrated in FIG. 3, the simplicity of ahigh definition mold comprising a plurality of cavities as shown in FIG.3, allows a worker to construct and make masonry-like units in anefficient and quick manner which significantly reduces time and cost ofproduction. Such a mold produces masonry-units with high definitionfront faces which will be facing out from the viewing side of the SAMU,while providing each masonry-like unit with a flat back face necessaryfor attachment to the netting means of the SAMU as described in detailbelow.

[0052] In order to produce the masonry-like units used to construct aSAMU, the first step entails designing a high definition open tray moldthat reflects the desired final appearance of each masonry-like unitthat will be used in the production of the decorative facing. Aplurality of different pattern types used for the production ofmasonry-like units are shown in the three different designs of highdefinition open tray molds as illustrated in FIGS. 3A-C. Suchmasonry-like units may be simulated brick, stone-work, any type ofmasonry work or may simulate natural material such as marble.

[0053] The process of making a high definition mold is well known tothose skilled in the art and practically any type of mold structure maybe used to construct the masonry-like units of the present invention.The composition of the high definition mold itself may encompass any orall of the following characteristics, wherein it may be made from a highdefinition silicone rubber compound, or similar such material, havingattributes which will allow one to achieve numerous high definitionreplications of the desired surface texture on the final masonry-likeunits produced. In addition the high definition molds may be formed frommaterial which is easy to clean upon the removal of a masonry like unit,which provides a means for quick turn around for the reuse of saidmolds. The high definition molds may be a vacuum formed or mold injectedplastic, polymer or other synthetic material. The materials chosen willultimately depend on the desired finished pattern for the masonry-likeunits and whether or not the pattern will be reproduced many times,i.e., the mold may be used for a single customized project or may beused for a large commercial production run.

[0054] Prior to pouring the gypsum cementitious material the cavity orcavities of the high definition open tray mold may be coated or treatedwith a parting agent to assist in the removal of the masonry-like unitsfrom the high definition open tray mold upon completion of the curingprocess. The type and amount of parting agent used will depend on thetype of hardening material or materials used to construct themasonry-like units of the present invention.

[0055] When making high definition molds to be sold in a kit format, oneoption may be to construct a mold using non-durable or bio-degradablematerials that would render the mold functional for creating a limitednumber of masonry-like units. For example, if the kit is designed formaking SAMUs with a brick-wall pattern, as exemplified in FIG. 5, forone accent wall (for example, a living room or den), the mold may beconstructed from a degradable or recycled material such as a very lowgrade polyvinyl chloride (PVC) or ABS plastic, on the order of 1 to 2 mmthick. Such a mold may be recycled in order to produce new molds withdifferent patterns or other types of recycled products, if one sodesired. The outer rim size of the mold may vary. Preferably 32 ft² to36 ft² is a desirable size that is small enough such that it is easy tomanipulate, yet large enough to produce a plurality of masonry-likeunits. A kit-sized high definition mold would preferably be on the orderof 16 ft².

[0056] In one embodiment at least a 4 foot by 4 foot high definitionmold is prepared from a vacuum formed plastic which will impart anoverall bold repetitive pattern, such as brick in FIG. 4, with a subtlerandom appearance, i.e., each brick-like unit is not identical inappearance. Once the mold has been completed, and the hardening materialpoured into the individual cavity or cavities the masonry-like units areallowed to cure and harden. The curing time for masonry-like units willdepend on the type of hardening material used and usually takes from 24to 48 hours. For example a gypsum cement can take from 4 to 24 hours tocure and harden. Once the masonry-like units are hardened they can beremoved from the mold and each cavity is cleaned of any debris so thatthe mold can be used again to form more masonry-like units if desired.Prior to forming more masonry-like units, a releasing or parting agentis applied to the cavity or plurality of cavities of the high definitionopen tray mold. The release agent is preferably a wax, oil, or siliconebased product wherein the use of such a releasing agent is notdetrimental to the structural integrity of the mold and is notdetrimental to the high definition surface of the masonry-like units.

[0057] Construction of the Articulating Structure

[0058] Masonry-like units are placed into an articulating structure,wherein said units can be arranged in any manner or pattern desiredincluding, but not limited to, such configurations as diamond, herringbone, mosaic-type, star, square, or T-bone patterns. Articulatingstructures have a plurality of cavities to loosely hold one or moremasonry-like units constructed using the high definition open tray moldof the present invention. Such articulating structures can be formmatched to reflect the design of the high definition mold or may bedesigned to reflect an entirely different pattern or patterns.Similarly, a pattern that is familiar to one of skill in the art may beutilized; however, custom design patterns can also be produced using themethod and articulating structures detailed in the present invention.

[0059] With reference to FIGS. 6, 7 and 8, the simplicity of thearticulating structure renders freedom to design almost any size, typeand shaped sheet of articulated masonry-like units, SAMU, and it maydramatically decrease the time and cost of producing and constructingsuch decorative facings. Further, articulating structures may beproduced to match the form of the high definition open tray mold. Suchunits are referred to as “form matched” articulating structures.

[0060] In one embodiment of the present invention and with reference toFIG. 9, the articulating structure may provide a means for theproduction of a SAMU with a brick wall pattern. The masonry-like unitsmay be set in any unique pattern or design which the user of the productdesires as illustrated in FIGS. 7 and 8. Using the masonry-like unitsand method of the present invention, it is possible to create a patternthat is not entirely repetitious in its fme detail. This design featureis lost with all other artificial coverings or masonry-like structuresbecause the cost of producing such a large surface area warrants arepetitive design.

[0061]FIG. 6B is a schematic of FIGS. 7 and 8. A myriad of differenttype patterns can be designed using the articulating structures 200 ofthe present invention, examples of which are depicted in FIG. 6C. Eacharticulating structure 200 may or may not be form matched as depicted inFIG. 6B to the corresponding high definition open tray mold which wasused to create the masonry-like units. Articulating structures 200 maybe designed in such a manner as to allow for one or more masonry-likeunits 220 to be placed into each holding cavity 210 as shown in FIGS. 6Aand 6C. The holding cavities 210 may be any shape. In one embodiment,the holding cavities 210 are rectangular and the perimeter 230 of eachholding cavity 210 is raised to loosely hold one or more masonry-likeunits 220, face down in the articulating structure 200.

[0062]FIGS. 7 and 8 depict an articulating structure in the shape of abrick wall. The simplicity of an articulating structure as defining anupwardly open tray or an open tray comprising a plurality of cavities asshown in FIGS. 6A-C, 7 and 8, provide a means for a worker to constructpatterns for SAMUs in a quick and simple manner. The composition of thearticulating structure itself may encompass any or all of the followingcharacteristics. It may be made from a high definition silicone rubbercompound, a vacuum formed or mold injected plastic, polymer or othersynthetic material, aluminum, steel, other metals, wood or compositesthereof. The materials chosen will ultimately depend on the desiredfinished pattern for the masonry-like units and whether or not thepattern will be reproduced many times, i.e., the form matchedarticulating structure may be used for a single customized project ormay be used for a large commercial production run.

[0063] In one embodiment of the present invention, the articulatingstructures may be sold in a kit format and as such it may be desirableto construct an articulating structure using non-durable orbio-degradable materials that would render the articulating structurefunctional for creating a limited number of SAMUs. For example, if thekit is designed for making SAMUs with a brick-wall pattern for oneaccent wall (for example a living room or den), the articulatingstructure may be constructed from a degradable or recycled material suchas a very low grade polyvinyl chloride (PVC) or ABS plastic, on theorder of 1 to 2 mm thick. Such an articulating structure may be recycledin order to produce new articulating structures with different patternsor other types of recycled products, if one so desired.

[0064] The outer rim size of an individual articulating structure mayvary. Preferably 32 ft² to 36 ft² is a desirable size that is smallenough that it is easy to manipulate, yet large enough to produce aplurality of SAMUs. A kit-sized articulating structure would preferablybe on the order of 16 ft². In one embodiment at least a 4 foot by 4 footarticulating structure is prepared from a vacuum formed plastic whichwill impart an overall bold repetitive pattern, such as brick, with asubtle random appearance, i.e., each brick-like unit is not identical inappearance. Once the articulating structure has been completed theproduction of the SAMU may begin.

[0065] Selection and Laying of Patterns Used to Construct SAMUs

[0066] With reference to FIGS. 7 and 8, a SAMU having masonry-like unitssimulating bricks, can completed in the following manner. Masonry-likeunits, for example brick-like units as depicted in FIG. 1 and 2, arelaid face down in an articulating structure so that once completed, theside of the masonry-like units which faces down will become the primaryviewing side of the SAMU. The articulating structure is designed so thatthe height of each masonry-like unit, once placed in the articulatingstructure, is above that of the articulating structure. The articulatingstructure may be designed so that each masonry-like unit is at least{fraction (1/16)}th of an inch higher than the height of thearticulating structure itself. This feature is key for the easy removalof the SAMU from the articulating structure. With reference to FIG. 10,a cross sectional schematic of the articulating structure used in thismanner is depicted, wherein the cross section is illustrated at twostages of the formation of a SAMU. The void 360, which is formed in theabove manner is schematically illustrated. This method allows the SAMUto dry separately away from and above the articulating structure, whichhelps to prevent the SAMU from adhering to the articulating structure.In one embodiment the masonry-like units are light weight gypsummasonry-like units of various colors. Any wall pattern can be chosen ordesigned by a worker in a simple and quick manner. A distinct advantageof the present invention over the prior art is the ability of havingcomplete design freedom. Any design pattern imaginable for a SAMU may beattainable using this invention.

[0067] Many designs for SAMUs are possible using the present invention.For example, if one wanted to design a theme room such as a cave,appropriate articulating structures could be constructed to create SAMUswith a cave-like relief. These articulating structures would generateflexible SAMUs that if wrapped around a curved structure or structuresand attached to a wall, ceiling or floor, such as columns, pillars orsupport beams, would simulate vertical support structures made of brickor stone. In contrast to typical pre-fabricated surface-coveringoptions, the simplicity of the articulating structure enables a freedomof design which not found in other methods of manufacture forpre-fabricated wall coverings.

[0068] Formation of a Sheet of Articulated Masonry-like Units

[0069] In one embodiment, masonry-like units, whether simulating masonryunits such as brick, adobe or concrete blocks or natural masonry-likeunits like stone flagstone or marble for example, are placed into anarticulating structure in order to form a SAMU. The masonry-like unitscan be arranged in any manner or pattern desired including, but notlimited to, such configurations as diamond, herring bone, mosaic-type,star, square, or T-bone patterns. Articulating structures have aplurality of cavities to loosely hold one or more masonry-like unitsconstructed using the high definition open tray mold of the presentinvention. Such articulating structures can be form matched to reflectthe design of the high definition mold or may be designed to reflect anentirely different pattern or patterns. Similarly, a pattern that isfamiliar to one of skill in the art may be utilized; however, customdesign patterns can also be produced using the method and articulatingstructures detailed in the present invention.

[0070] As discussed in Example 1 below, one embodiment of the presentinvention is the formation of a SAMU simulating a brick wall pattern.However, it may be envisioned that SAMUs may be produced usingmasonry-like units other than brick-like units that are made with thehardening material of the present invention. Such masonry-like units mayinclude, but are not limited to, stone, adobe or marble. Thesestructural material pieces are made in order to simulate the “look” ofthese materials in their natural state.

[0071] In one embodiment of the present invention a SAMU is formed bythe placement of a plurality of masonry-like units into an articulatingstructure in a desired fashion and subsequently these masonry-like unitsare interconnected by use of a mesh-adhesive which is distributed overthe back surface of the masonry-like units thus interconnecting saidunits forming a SAMU.

[0072] In one embodiment of the present invention, the mesh-adhesiveafter application to the base of the masonry-like units, maintains itsopen weave portions wherein upon installation of a SAMU the installationor filler material, which may be mortar, is able to pass through saidopen weave portions enabling the filling of the separation distancebetween the masonry-like units of a SAMU. This process provides a meansfor reducing the amount of work required to produce realistic masonrytype cladding, since the process of pointing of the spaces between themasonry like units is partially or fully performed by the abovementioned process. In one embodiment of the present invention, the openweave portions have a mesh size ranging from 1 mm² to 30 mm².

[0073] In one embodiment of the present invention and with reference toFIG. 11A the mesh-adhesive is a combination of a mesh netting means andan adhesive, which serves to form a sheet-like material and impartflexibility to the finished product. This enables the final SAMU to beeasily manipulated and attached onto curved surfaces. There are manysynthetic or natural materials which may be used as the mesh netting forthis purpose including but not limited to glass fiber, nylon, or any manmade mesh-like substance which is resistant to the inherent alkalinityof a cementitious material. FIG. 11A illustrates a schematic of thefront and back side of a SAMU created using this type of mesh-adhesive.

[0074] In another embodiment of the invention and with reference to FIG.11B the mesh-adhesive can be a random pattern of adhesive, for examplelatex glue or a polymer based glue. The mesh-adhesive may be applied tothe masonry-like units in the articulating structure from top to bottomand end to end of the articulating structure random pattern. In such anembodiment the glue material must filly harden before removing thebrick-like unit wall patterned SAMU from its corresponding articulatingstructure. FIG. 11B illustrates a schematic of the front side and backside of a SAMU created using this type of mesh adhesive. In thisembodiment of the present invention, the mesh-adhesive may be spreadover the back surface of the masonry-like units in such a manner that aneven distribution of said mesh-adhesive is realized over the surface ofthe SAMU.

[0075] The following procedure is used in order to make a complete SAMU.Masonry-like units, simulating bricks in this example, are placed facedown in an articulating structure. In one embodiment the mesh-adhesiveis a combination of a fine mesh material and an adhesive. A piece offine mesh netting is stretched over the entire surface area of themasonry-like units, leaving a 3 inch overlap on the top side of thearticulating structure. Although facings can be made without overhang,in one embodiment the mesh netting material is cut to a dimensionensuring an overhang of at least 3 inches along the top edge of theSAMU, as illustrated in FIG. 9.

[0076] In one embodiment of the present invention, netting is adhered tothe masonry-like units using for example a commercially available latexglue by brushing the glue on using a foam roller, as illustrated in FIG.12. In one embodiment one coat of latex glue applied to the non-viewingside of the masonry-like units in the articulating structure issufficient to attach the mesh material to the masonry-like units.However, it will become clear to a worker of ordinary skill when morethan one coat of glue is required to secure the mesh to the masonry-likeunits and when the mesh net is firmly attached to the gypsummasonry-like units in such a manner that the netting does not peal awayfrom the masonry-like units. The mesh adhesive and masonry-like unitsthat are interconnected in this manner form a SAMU, as illustrated inFIG. 9.

[0077] In one embodiment of the present invention, a SAMU may beproduced using automation wherein each of the steps as described abovemay be performed by a machine which therefore may reduce the productiontime for a SAMU and furthermore may reduce costs.

[0078] Removing the SAMU from the Articulating Structure

[0079] Once the glued masonry-like units and the mesh-adhesive dry andthe formed SAMU is hard to the touch, it is ready to remove from thearticulating structure. One embodiment is to lift the SAMU out of thearticulating structure by lifting the mesh-adhesive that extends beyondthe edge of the upper most layer of masonry-like units. In oneembodiment the mesh-adhesive may take between 20 to 40 minutes to cureand dry to the masonry-like units, depending on the brand used, beforethe SAMU is hard to the touch and removal from the articulatingstructure can be attempted.

[0080] In embodiments where it is desired to have interlocking panels,portions of the SAMU can be cut out using a knife. This will generatespaces that can be filled in by the protruding pieces on an adjacentSAMU.

[0081] In one embodiment, an elongated piece of wood is placed along oneedge of the SAMU as it sits in the articulating structure such that theoverhanging mesh net member can be wrapped around the piece of wood andattached as illustrated in FIG. 13 by means including stapling, nailing,screwing or other fastening means. The cured SAMU can then be gentlypried from the articulating structure beginning with the edge that isfastened to the plywood strip. The SAMU is then placed in a warm dryarea, preferably with low humidity conditions, for the remainder of thecuring period after which it will be ready for installation.

[0082] Attaching a SAMU to a Surface

[0083] The method of attachment for one preferred embodiment includesattaching SAMUs to a surface using an industrial mortar which spreadsthe adhesive force over the entire surface of the SAMU and serves tosustain the shape, look, weight and structural integrity of the entireSAMU. Guiding lines can be placed on the wall for proper alignment ofthe facings. FIG. 13 shows how the support beam may be used to “hang”the facing following the hardening of the meshadhesive wherein in thisfigure, a worker has screwed the beam to the wall. This mode ofattachment is in contrast to rigid points of attachment such as nails orclips, which focuses the support to the point of attachment. Althoughnails or screws may be used to hold the SAMUs in place duringinstallation, these are eventually removed, such that a uniformdecorative wall is manufactured with little or no visible gaps orlining. In one embodiment the SAMU is pressed against a mortar materialthat was previously applied to a wall or surface to be decorated. Themortar flows through the mesh portion of the SAMU to form the groutingof the SAMU and to hold the SAMU including the masonry-like units, inplace. An enlargement of such a SAMU is illustrated in FIG. 14. Removalof excess mortar (grout) is taken off the SAMU using a proper mortartool known to a person of skill in the art of masonry pointing.

[0084] Construction of a rectangular SAMU is demonstrated by FIG. 13wherein the masonrylike units are brick-like units, and mortar lines arein coplanar relation with a top edge portion, a bottom edge portion, andtwo side edge portions and wherein the finished product has athreedimensional quality when mounted on a wall or fireplace eithervertically or horizontally. All SAMUs are mounted in such a way as tomask the points ofjuncture between two or more SAMUs mounted on a wall.The top edges of these SAMUs are likewise made to simulate a mortarline, however, the free ends of these edge portions can optionally betrimmed back to the upper edge and/or the lower edge of the masonry-likeunits to allow for the union of a further panel.

[0085] SAMUs can be mounted above, below or beside one another, ineither a horizontal or vertical orientation, depending upon therequirements of the area to be covered. After mounting the SAMU to awall, the space between the masonry-like units along the upper edge ofone SAMU and the masonry-like units along the lower edge of a co-planermounted SAMU can be filled in with mortar to hide the junction betweenthe two SAMUs.

[0086] The dimensions of each SAMU can vary, depending upon thedimensions of the wall to be covered, the number of people working toconstruct and mount each SAMU onto a wall, the design of the relief, andthe type and shape of the articulating structure used. In general,dimensions will be chosen in order to maintain an economical cost bothfor making and installing such SAMUs. The larger the SAMU, the fewernumber of SAMUs required to cover a wall surface, which diminishes theamount of work invested to mask seams. On the other hand, the SAMUscannot be so large as to be unwieldy to manipulate and install in smallenclosures such as a wine cellar or basement. The height of each SAMUcan range significantly, with a typical height being from 1 foot to 8feet, and the height of preferred embodiments being on the order of 4 to5 feet. The width can range significantly, with a typical width rangingfrom 2 to 14 feet, and one width being on the order of 4 to 6 feet. Itcan be envisioned that both the height and width of a SAMU can begreater that 8 feet and 14 feet, respectively and may depend upon theheight and width of the structure to be covered or on the inclination ofa particular designer.

[0087] In one embodiment, the exterior boarders of the SAMUs producedwith the method of the present invention are rectangular in shape.However, depending upon the requirements of the wall surface desired tobe covered, SAMUs may be produced with exterior boarders that are otherthan rectangular. Such shapes may include, but are not limited to,circular, square, triangular, rhomboid and any other shape envisioned bythe user of the present invention in order to properly cover the wallsurface of interest.

[0088] Supplemental Features

[0089] If spaces are left surrounding the masonry-like units, filler canbe added after the SAMUs are attached to the wall. This will reduce toan even greater extent any “pre-fabricated”appearance and multi-coloredmasonry-like units with a mortar-like material will be rendered evenmore realistic. However, by using the method of the present inventionthis course of action is usually not necessary.

[0090] The face of these SAMUs can be painted to more closely simulatenatural products or a wall constructed of natural products, such asstone or marble or other like masonry-like units.

[0091] Though not strictly considered part of this invention, foammaterial may be applied to the back of the SAMU, after the SAMU hashardened, to provide an insulating feature.

[0092] One skilled in the art will recognize that modifications may bemade in the present invention without deviating from the scope of theinvention. The invention is illustrated further by the following examplewhich is not to be construed as limiting the invention or scope of thespecific procedures, constructions, components or compositions describedherein.

EXAMPLES

[0093] The following example illustrates the method used to constructdecorative Sheets of Articulated Masonry-like Units, SAMUs, that achievethe appearance of a brick wall. Gypsum cementitious material has beenutilized to form light-weight masonry-like units, hereinafter referredto as brick-like units, in order to produce SAMUs using the method ofthe present invention because it is desirable and necessary to achievethe appearance of brick while at the same time decrease the costsincurred when constructing an entire brick wall.

[0094] Brick Wall Shaped High Definition Open Tray Mold

[0095] The simplicity of a high definition mold as defining an upwardlyopen tray mold or an open tray mold comprising a plurality of cavitiesas shown in FIG. 3, allows a worker to construct and make brick-likeunits in an efficient and quick manner which significantly reduces timeand cost of production. Such a mold produces brick-like units with highdefinition front faces which will be facing out from the viewing side ofthe SAMU. Use of the high definition open tray mold and method of theinvention produces brick-like units with flat back faces whichfacilitates the attachment of the brick-like units to the netting meansof the SAMU. However, brick-like units produced using the highdefinition mold 100 depicted in FIG. 3B of the present invention, mayhave a back face which is not entirely flat and may be slightly rough orbumpy. A rough back face may be required to better adhere the meshnetting means to the brick-like units, depending upon the materialcharacteristics of the mesh netting means to be glued to the brick-likeunits in order to make the SAMU.

[0096] In order to produce the brick-like units used to construct aSAMU, the first step entails designing a high definition open tray moldthat reflects the desired final appearance of each brick-like unit thatwill be used in the production of the decorative facing. Examples of theplurality of different brick pattern types used in the production ofbrick-like units are shown in the high definition open tray molddepicted in FIG. 3B. Individual molds may be designed to produce clonesof one type, shape, size or color of brick-like unit, or in such amanner as to produce brick-like units of different type, shape, size orcolor within a single high definition open tray mold.

[0097] Preparing the Hardening Material Mixture (Gypsum Cement) andProducing Brick-like units

[0098] In one embodiment gypsum cement, is prepared and poured into abrick wall shaped high definition open tray mold in order to make thebrick-like units, which will be used as the facing material for theSAMU. The hardening material can be of many types, the definingcharacteristics include the fact that, within a practical period of timeafter mixing with an appropriate diluent, for example water, thematerial hardens and does not crumble or otherwise significantly looseits integrity over the lifetime of the SAMU. The hardening material maybe any cementitious or non-cementitious compound, preferably but notlimited to gypsum cement, plaster-of-Paris or an acrylic based compound.The material chosen will once again depend on the desired final textureas well as considerations of weight, wear and costs of the project.

[0099] The preferred ratio of dry gypsum cement powder to water is 4to 1. The gypsum cement mixture is stirred until said mixture is free oflumps and is of a smooth creamy consistency. In one embodiment, one ormore commercially available dyes, known to a worker skilled in the art,may be added to the gypsum cement mixture, in order to produce coloredbrick-like units, before or after pouring said mixture into theplurality of cavities, 110, of the high definition open tray mold 100.Colors may include, but are not limited to, burnt orange, orange, red,gray, black, brown, tan, beige, or white. Brick-like units can beremoved from the high definition mold in as little as 30 min forbrick-like units with a width of less than ⅛ of an inch. In oneembodiment masonry-like units are about ⅛ to ¾ of an inch in thicknessand are dried for about 4 to 24 hours.

[0100] Selection and Laying of Patterns Used to Construct SAMUs

[0101]FIG. 7 depicts a worker laying brick-like units face down in anarticulating structure so that once completed, the side of thebrick-like units which faces down will become the primary viewing sideof the SAMU. The articulating structure is designed so that the heightof each brick-like unit, once placed in the articulating structure, isabove that of the perimeter 230 of the holding cavity. The articulatingstructure may be designed so that each brick-like unit is at least{fraction (1/16)}th of an inch higher than the height of thearticulating structure itself. This feature is key for the easy removalof the SAMU from the articulating structure. This method allows the SAMUto dry separately away from and above the articulating structure, andhelps to prevent the SAMU from adhering to the articulating structure.Any wall pattern can be chosen or designed by a worker in a simple andquick manner. A distinct advantage of the present invention over theprior art is the ability of having complete design freedom. Any designpattern imaginable for a SAMU may be attainable using this invention.

[0102] Formation of a Brick Wall Patterned Sheet of ArticulatedMasonry-like Units

[0103] The following procedure is used in order to make a complete brickwall shaped SAMU. Brick-like units are placed face down in anarticulating structure. Although facings can be made without overhang,in one embodiment a piece of fine mesh netting is stretched over theentire surface area of the brick-like units leaving a 3 inch overlap onthe top side of the articulating structure. Mesh netting may be any typeof fine mesh, one embodiment being a mesh netting that is light weight.In yet another preferred embodiment a random pattern of adhesive,applied as discussed above, may serve as the mesh-adhesive means for theSAMU.

[0104] Netting is adhered to the brick-like units using a commerciallyavailable latex glue by brushing the glue on using a foam roller, asillustrated in FIG. 12. In one embodiment one coat of latex glue appliedto the non-viewing side of the brick-like units in the articulatingstructure is sufficient to attach the mesh material to the brick-likeunits. However, it will become clear to a worker of ordinary skill whenmore than one coat of glue is required to secure the mesh to thebrick-like units and when the mesh net is firmly attached to the gypsumbrick-like units in such a manner that the netting does not peal awayfrom the brick-like units. In one embodiment the glue will take between20 to 40 minutes to cure and dry to the brick-like units, depending onthe brand used, before the SAMU is hard to the touch and removal fromthe articulating structure can be attempted. The mesh netting andbrick-like units that are glued together in this manner form a SAMU, asillustrated in FIG. 9.

[0105] Removing the SAMU from the Articulating Structure

[0106] Once the glued brick-like units and net dry and the formed SAMUis hard to the touch, it is ready to remove from the articulatingstructure. One embodiment is to lift the facing out of the articulatingstructure by lifting the mesh netting means that extends beyond the edgeof the upper most layer of brick-like unit. In one embodiment, anelongated piece of wood, preferably a 2 by 4 or a piece of plywood, isplaced along one edge of the SAMU as it sits in the articulatingstructure such that the overhanging mesh net member can be wrappedaround the piece of wood and stapled, as shown in FIG. 13, nailed,screwed or otherwise fastened to the beam. The cured SAMU can then begently pried from the articulating structure beginning with the edgethat is fastened to the plywood strip. The SAMU is then placed in a warmdry area, preferably with low humidity conditions, for the remainder ofthe curing period after which it will be ready for installation.

[0107] Attaching a SAMU to a Surface

[0108] The method of attachment for one preferred embodiment includesattaching SAMUs to a surface using an industrial mortar which spreadsthe adhesive force over the entire surface of the SAMU and serves tosustain the shape, look, weight and structural integrity of the entireSAMU. Guiding lines can be placed on the wall for proper alignment ofthe facings. FIG. 13 shows how the support beam may be used to “hang”the facing following the adhesive hardening. In this figure, a workerhas screwed the beam to the wall. This mode of attachment is in contrastto rigid points of attachment such as nails or clips, which focuses thesupport to the point of attachment. Although nails or screws may be usedto hold the SAMUs in place during installation, these are eventuallyremoved, such that a uniform decorative wall is manufactured with littleor no visible gaps or lining. In one embodiment the SAMU is pressedagainst a mortar material that was previously applied to a wall orsurface to be decorated. The mesh netting means must have a lattice withholes of sufficient diameter to allow mortar to flow through the meshnetting means of the SAMU to the front viewing face of the SAMU. Themortar flows through the mesh portion of the SAMU to form the groutingof the SAMU and to hold the SAMU including the masonry-like units, inplace. An enlargement of such a SAMU is illustrated in FIG. 14. Aclose-up view of an attached SAMU is shown in FIG. 5. Removal of excessmortar (grout) is taken off the SAMU using a proper mortar tool known toa person of skill in the art of brick laying. Mortar may be added to anygaps in the SAMU if necessary, using a mortar tool.

[0109] It is to be understood that the exemplary embodiments containedherein are illustrative and not restrictive. It will be obvious to thoseskilled in the art that various modifications, adaptations andvariations may be made without departing from the teaching of theinvention.

I claim:
 1. A method of forming a sheet of articulated masonry-likeunits using the sequential steps comprising: a) obtaining masonry-likeunits having a base portion ranging in size from about ⅛ to 2 ½ inchesin thickness prepared from one or more hardening materials selected fromthe group gypsum cement, plaster of Paris, Portland cement, anacrylic-based resin with cementitious material and cementitiousmaterial; b) placing said masonry-like units into an articulatingstructure with a plurality of separate holding cavities to hold one ormore masonry-like units at least {fraction (1/16)} of an inch above theheight of the upper edge of said articulating structure; c)interconnecting the masonry-like units to each other using amesh-adhesive thereby generating a sheet of articulated masonry-likeunits, wherein sufficient space is present between each masonry-likeunit sufficient to enable an installation or filler material to enterbetween adjacent masonry-like units and pass through the open weaveportions of said mesh adhesive.
 2. The method of forming a sheet ofarticulated masonry-like units according to claim 1, wherein saidmasonry-like units comprise a high definition front face shaped to looklike masonry material selected from the group of bricks, stones,flagstones, marble and any type of masonry work or millwork, and whereinsaid masonry-like units comprise a generally flat back face and sidesnecessary for attachment to the mesh adhesive.
 3. The method of forminga sheet of articulated masonry-like units according to claim 1, whereinsaid masonry-like units are brick-like units.
 4. The method according toclaim 2, wherein said mesh-adhesive is formed by: placing a meshselected from the group of glass fiber, nylon, fiberglass and anymaterial that is resistant to the alkalinity of said hardening materialover said masonry-like units; and b) applying an adhesive over said meshto form said mesh-adhesive.
 5. The method according to claim 4, whereinsaid mesh-adhesive is formed by placing an adhesive onto and over saidmasonry-like units in a random pattern.
 6. The method according to claim5, wherein said adhesive is latex glue or a polymer-based glue.
 7. Asheet of articulated masonry-like units produced according to the methodof claim
 1. 8. A sheet of articulated masonry-like units producedaccording to the method of claim
 3. 9. A kit to produce a sheet ofarticulated masonry-like units comprising separately; a) an articulatingstructure shaped to simulate any wall, ceiling, or building typestructure constructed with masonry units; b) masonry-like units; c) meshnetting means; d) adhesive; e) adhesive application means; f) mortarmaterial(s); and g) instructions for use.
 10. A kit having a sheet ofarticulated masonry-like units comprising separately; a) a sheet ofarticulated masonry-like units; b) mortar material(s); and c)instructions for use.